Double-meter unit alignment method

Abstract

The invention belongs to the field of industrial equipment measurement, and provides a double-meter method unit alignment method, which comprises the following steps of: mounting a magnetic meter frame on the excircle surface of a water pump half-coupling, mounting a radial dial indicator on the excircle surface of a motor half-coupling, measuring the radial deviation value of a motor shaft, and mounting an axial dial indicator on the inner side of the end surface of the motor half-coupling. Measuring the axial deviation value of a motor shaft, taking the clockwise rotation of the coupler as the forward direction, measuring the radial deviation values of the dial indicator at four points of 0 degree, 90 degrees, 180 degrees and 270 degrees of the coupler, recording the radial deviation values as a1, a2, a3 and a4, measuring the corresponding axial deviation values as s1, s2, s3 and s4, calculating the accumulated deviation value Ch of the deviation in the horizontal direction, and calculating the accumulated deviation value Cv of the deviation in the vertical direction, calculating alignment positions X1, X2, Y1 and Y2 of the unit according to a measurement result; by means of accurate measurement of the magnetic gauge stand and the dial indicator, the time required by repeated adjustment and multiple attempts in a traditional alignment method is greatly shortened, and therefore the efficiency of alignment work is remarkably improved.

Description

Technical Field

[0001] The invention belongs to the technical field of industrial equipment measurement, in particular to a double-meter unit alignment method. Background Art

[0002] In the industrial field, especially in industries involving rotating machinery, such as water conservancy projects, petrochemicals, electric power and metallurgy, it is crucial to ensure the precise alignment of mechanical equipment. Precise alignment can prevent additional stress, vibration and possible equipment damage caused by coupling misalignment, thereby improving the operating efficiency and service life of the equipment. Traditionally, the alignment of the unit relies on basic measuring tools such as rulers and feeler gauges for preliminary alignment, followed by more precise measurements using dial indicators. This process is not only time-consuming and labor-intensive, but also has high requirements on the professional quality and experience of the operator. Even so, traditional methods often require repeated adjustments and multiple attempts to achieve the ideal alignment effect, which not only prolongs the downtime of the equipment, but may also affect production efficiency. This problem is particularly prominent in the installation and maintenance of large-scale unit equipment.

[0003] In addition, the existing alignment methods lack automated and intelligent adjustment strategies, and cannot monitor and predict dynamic changes in the adjustment process in real time, resulting in a certain degree of blindness and uncertainty in the alignment process. In actual operation, due to environmental factors and human operation errors, the accuracy and reliability of traditional alignment methods still need to be improved.

[0004] In view of this, it is necessary to develop a new unit alignment method to solve the problems of low efficiency, insufficient precision, and complex operation in the existing technology.

[0005] Therefore, those skilled in the art have proposed a double-meter unit alignment method to solve the problems raised by the background technology. Summary of the invention

[0006] In order to solve the above technical problems, the present invention provides a double-meter method for aligning a unit to solve the problems of low efficiency, insufficient precision, complex operation, etc. existing in the prior art.

[0007] A double-meter method for aligning a unit, comprising S1. installing a magnetic meter stand on the outer surface of a water pump half coupling;

[0008] S2. Install a radial dial indicator on the outer surface of the motor half coupling to measure the radial deviation of the motor shaft;

[0009] S3. Install an axial dial indicator on the inner side of the motor half coupling end face to measure the axial deviation of the motor shaft;

[0010] S4. Take the clockwise rotation of the coupling as the positive direction, measure the radial deviation values ​​of the dial indicator at the four points of 0°, 90°, 180° and 270° of the coupling, record them as a1, a2, a3, a4, and measure the corresponding axial deviation values, record them as s1, s2, s3, s4;

[0011] S5. Determine the initial alignment state of the coupling by measuring the initial radial deviation value a 1init , a 2init , a 3init , a 4init and initial axial deviation value s 1init ,s 2init ,s 3init ,s 4init ;

[0012] S6. Calculate the mean and standard deviation of the initial alignment deviation, and calculate the mean of the radial and axial deviations based on the data of S5. a , Mean s , and the variance of radial and axial deviations StdDev a , StdDev s ;

[0013] S7. Calculate the cumulative deviation value C of the horizontal deviation h , calculate the cumulative deviation value C of the vertical deviation v ;

[0014] S8. According to the measurement results, the computer group finds the positions X1, X2, Y1, and Y2.

[0015] Preferably, the magnetic meter frame in S1 is made of neodymium iron boron material to provide stable supporting force, and the magnetic meter frame includes an adjustable magnetic control mechanism; the selection and installation of the radial dial indicator in S2 adopts mechanical structure installation and shockproof design, and the installation position of the axial dial indicator in S3 is designed to be a certain distance from the central axis of the coupling, and the installation adopts a bolt installation method.

[0016] Preferably, the calculation method in S6 is:

[0017] Calculation of the mean and standard deviation of the misalignment helps assess the consistency and range of the initial alignment.

[0018] Preferably, in S7 This formula provides the cumulative value of the deviation of the two axes in the horizontal and vertical directions, which helps to further analyze and adjust the spatial position relationship of the two axes.

[0019] Preferably, the calculation formula of X1 and X2 in S8 is: When X1>0, “the front foot is padded”; when X1<0, “the front foot is padded”; when X2>0, “the back foot is padded”; when X2<0, “the back foot is padded”.

[0020] Preferably, the calculation formula of Y1 and Y2 in S8 is: When Y1>0, the front foot moves to a2, when Y1<0, the front foot moves to a4, when Y2>0, the back foot moves to a2, and when Y2<0, the back foot moves to a4.

[0021] Preferably, in the measurement data of S4, when s1>s3, it is judged as upper opening; when s1=s3, it is judged as two axes are parallel;

[0022] When s2>s4, it is judged as front opening, and when s2>s4, it is judged as two axes are parallel.

[0023] Preferably, the measurement data in S4 must meet the following conditions: a1+a3≈a2+a4; s1+s3≈s2+s4. If the above conditions are not met, the influence of shaft movement or loosening of anchor bolts must be eliminated.

[0024] Preferably, during the calculation process, S8 also needs to calculate the total deviation value T of the coupling, which is used to evaluate the overall size of the coupling deviation. The smaller the T value, the higher the coupling alignment accuracy.

[0025] A double-meter method unit alignment program product includes accurate measurement, using two dial indicators to respectively measure the radial and axial alignment of the coupling to achieve accurate measurement;

[0026] The data analysis unit provides data analysis functions and processes the measured data to ensure the accuracy and reliability of the alignment;

[0027] Data storage function unit records the process and results of each alignment to facilitate subsequent analysis and optimization;

[0028] The result judgment unit can judge the concentricity deviation between the motor shaft and the water pump shaft according to the measurement and analysis results, and give adjustment suggestions;

[0029] The user interface unit allows the user to input measurement values ​​and automatically calculates and displays the adjustment results, with a friendly interface and easy operation.

[0030] Through the above technical solution,

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] 1. The present invention adopts a double-meter method for aligning the unit, and utilizes the precise measurement of a magnetic meter stand and a dial indicator, which greatly reduces the time required for repeated adjustments and multiple attempts in the traditional alignment method, thereby significantly improving the efficiency of the alignment work.

[0033] 2. The dual-meter method of the present invention measures radial and axial deviations at different positions of the coupling and calculates the mean and standard deviation of the deviations, thereby evaluating the consistency and deviation range of the initial alignment state, effectively improving the accuracy and reliability of the measurement.

[0034] 3. The present invention reduces the dependence on the professional quality and experience of the operator through programmed method steps and automated data analysis, making the alignment process more standardized and simplified, facilitating the operator to quickly master and execute, and reducing the complexity of the operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 is a flowchart of the method; DETAILED DESCRIPTION

[0036] The following embodiments of the present invention are described in further detail in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0037] Embodiment 1: As shown in the attached Figure 1 As shown: The present invention provides a double-meter method for aligning a unit, comprising: S1. installing a magnetic meter stand on the outer surface of a water pump half coupling, the magnetic meter stand also having an adjustable magnetic force control mechanism, allowing the user to finely adjust the magnetic force according to the size and material properties of the coupling to meet the measurement requirements under different working conditions, thereby ensuring high accuracy and high repeatability of the measurement process;

[0038] S2. Install a radial dial gauge on the outer surface of the motor half coupling to measure the radial deviation of the motor shaft. The radial dial gauge is of high precision and is installed with a precise mechanical structure and a specially designed shockproof system to effectively isolate the vibration interference of the external environment and ensure the accuracy of the measurement data.

[0039] S3. Install an axial dial indicator on the inner side of the motor half coupling end face to measure the axial deviation of the motor shaft;

[0040] S4. Take the clockwise rotation of the coupling as the positive direction, measure the radial deviation value of the dial indicator at the four points of 0°, 90°, 180° and 270° of the coupling, record it as a1, a2, a3, a4, measure the corresponding axial deviation value, record it as s1, s2, s3, s4, measure at the four points of 0°, 90°, 180° and 270° of the coupling, not only covering the entire rotation cycle of the coupling, but also ensuring the comprehensiveness and representativeness of the measurement results through the measurement at the key angle points, providing a solid foundation for subsequent data analysis;

[0041] S5. Determine the initial alignment state of the coupling by measuring the initial radial deviation value a 1init , a 2init , a 3init , a 4init and initial axial deviation value s 1init ,s 2init ,s 3init ,s 4init , by accurately measuring the initial radial deviation and initial axial deviation, it provides an accurate starting point for centering adjustment;

[0042] S6. Calculate the mean and standard deviation of the initial alignment deviation, and calculate the mean of the radial and axial deviations based on the data of S5. a , Mean s , and the variance of radial and axial deviations StdDev a , StdDev s , calculate the mean and standard deviation of the initial alignment deviation, use statistical principles to conduct in-depth analysis of the measurement data, evaluate the consistency and deviation range of the initial alignment state, and provide a quantitative reference for subsequent adjustments;

[0043] S7. Calculate the cumulative deviation value C of the horizontal deviation h , calculate the cumulative deviation value C of the vertical deviation v , calculate the cumulative deviation value of the horizontal direction deviation and the cumulative deviation value of the vertical direction deviation, and provide comprehensive data support for precise adjustment by comprehensively considering the spatial position relationship of the two axes;

[0044] S8. The computer group aligns the positions X1, X2, Y1, and Y2 according to the measurement results, and provides detailed adjustment suggestions, including but not limited to "adding pads to the front feet", "reducing pads to the front feet", "adding pads to the rear feet" and "reducing pads to the rear feet", to ensure that the centering accuracy of the coupling meets the high standards required for industrial applications. At the same time, the method also includes a verification step for the adjustment results to ensure that the equipment can operate stably after alignment and achieve the expected performance indicators.

[0045] Furthermore, the magnetic meter frame in S1 is made of neodymium iron boron material, and its magnetic poles are arranged in a specific geometric shape to provide stable supporting force. At the same time, the magnetic meter frame includes an adjustable magnetic force control mechanism, allowing the user to adjust the supporting force according to the size of the coupling to adapt to couplings of different sizes, ensuring high accuracy and repeatability during the measurement process. The selection and installation of the radial dial indicator in S2 adopt mechanical structure installation and shockproof design; the installation position of the axial dial indicator in S3 is designed to be a certain distance from the central axis of the coupling to ensure the accuracy of the measurement and the installation of the axial dial indicator adopts a bolt installation method.

[0046] Embodiment 2: As shown in the attached Figure 1 As shown: This embodiment is basically the same as the previous embodiment.

[0047] From the above, it can be seen that the calculation method in S6 is:

[0048] Calculation of the mean and standard deviation of the misalignment helps assess the consistency and range of the initial alignment.

[0049] Preferably, in S7 This formula provides the cumulative value of the deviation of the two axes in the horizontal and vertical directions, which helps to further analyze and adjust the spatial position relationship of the two axes.

[0050] Furthermore, the calculation formula of X1 and X2 in S8 is: When X1>0, "front foot padding", when X1<0, "front foot padding", when X2>0, "rear foot padding", when X2<0, "rear foot padding", the calculation formula of Y1 and Y2 in S8 is, When Y1>0, the front foot moves to a2, when Y1<0, the front foot moves to a4, when Y2>0, the rear foot moves to a2, and when Y2<0, the rear foot moves to a4. The formula further includes the evaluation of the dynamic performance of the coupling. By analyzing the impact of the movement of the front and rear feet on the performance of the coupling, the program can predict the performance changes of the adjusted equipment and give corresponding optimization suggestions. In addition, vibration analysis technology can be introduced in the calculation process to evaluate the impact of the adjustment on the vibration level of the equipment and ensure the stability of the equipment after adjustment.

[0051] Specifically, in the measurement data of S4, when s1>s3, it is judged as an upper opening; when s1=s3, it is judged as two axes are parallel, when s2>s4, it is judged as a front opening, and when s2>s4, it is judged as two axes are parallel. The evaluation of S4 measurement data further includes consideration of the equipment operating environment. For example, when the measurement data shows "upper opening" or "front opening", the program will analyze whether this is caused by factors such as temperature and humidity in the equipment installation environment, and provide corresponding environmental adjustment suggestions. In addition, the program can also predict the changing trend of the opening type based on the equipment usage and historical data, providing a reference for the long-term maintenance of the equipment.

[0052] Preferably, the measurement data in S4 must meet the following conditions: a1+a3≈a2+a4; s1+s3≈s2+s4. If the above conditions are not met, the influence of shaft movement or loosening of anchor bolts needs to be eliminated, which can be further optimized by introducing an adaptive control algorithm. When the measurement data does not meet the given conditions, the program can automatically adjust the measurement parameters or provide calibration suggestions to eliminate the influence of shaft movement or loosening of anchor bolts. In addition, the program can also intelligently recommend calibration cycles and maintenance strategies based on the real-time status and historical maintenance records of the equipment to improve the reliability and maintenance efficiency of the equipment.

[0053] Specifically, the total deviation value T of the coupling needs to be calculated during the calculation of S8. Used to evaluate the overall size of the coupling deviation. The smaller the T value, the higher the coupling alignment accuracy. The total deviation value of the coupling is obtained by comprehensively considering the radial and axial deviation values ​​of all measuring points. This total deviation value not only reflects the deviation of the coupling in a single direction, but also provides a comprehensive deviation index for evaluating the accuracy of the entire coupling alignment state.

[0054] Embodiment 3: As shown in the attached Figure 1 As shown: Different from the previous embodiment, this embodiment provides a computer program product, including an instruction set for any of the above methods, including a precision measurement unit, using two dial indicators to respectively measure the radial and axial alignment of the coupling to achieve precise measurement. The precision measurement unit is the core component of this program. It uses a high-precision dial indicator to achieve precise measurement of the radial and axial deviations of the coupling. The unit uses advanced sensing technology to ensure the accuracy and repeatability of the measurement data. Through the stable positioning of the magnetic table stand and the fine reading of the dial indicator, the user can obtain reliable measurement results under various working conditions. In addition, the unit also has environmental adaptability and can resist the interference of environmental factors such as temperature and humidity to ensure measurement accuracy;

[0055] The data analysis unit provides data analysis functions and processes the measured data to ensure the accuracy and reliability of the alignment. The data analysis unit uses advanced algorithms to deeply process and analyze the measured data. It not only calculates the mean and standard deviation, but also evaluates the consistency and deviation range of the data through statistical methods. The unit can also identify and compensate for possible system errors to ensure the accuracy and reliability of the alignment results. Through intelligent data analysis, users can quickly obtain adjustment suggestions and greatly improve decision-making efficiency;

[0056] The data storage function unit records the process and results of each alignment, which is convenient for subsequent analysis and optimization. The data storage function unit provides users with a powerful data management platform. The process and results of each alignment will be recorded in detail and stored in a structured format, which is convenient for users to perform historical data analysis and trend prediction. The unit supports batch import and export of data, allowing users to save data locally or in the cloud to ensure data security and accessibility. In addition, the unit also provides data backup and recovery functions to prevent data loss;

[0057] The result judgment unit can judge the concentricity deviation of the motor shaft and the water pump shaft according to the measurement and analysis results, and give adjustment suggestions. The result judgment unit automatically judges the concentricity deviation of the motor shaft and the water pump shaft according to the measurement and analysis results. It displays the deviation size and direction in a visual way and provides intuitive adjustment suggestions. The unit also has logical judgment capabilities and can intelligently recommend the best adjustment plan based on actual working conditions and historical data. In addition, the unit can also predict the performance of the adjusted equipment to help users evaluate the adjustment effect;

[0058] The user interface unit allows users to input measurement values ​​and automatically calculates and displays adjustment results. The interface is friendly and easy to operate. The user interface unit is designed with friendliness and ease of use in mind, providing an intuitive operating environment. Users can input measurement values ​​through a simple interface, and the program will automatically calculate and display adjustment results. The interface supports multi-touch operation, with quick response and clear feedback. The interface design takes into account the operating habits of different users and provides a variety of data input and result display methods. In addition, the interface also provides help and tutorials to guide users on how to measure and analyze, ensuring that users can quickly get started.

[0059] Preferably, the program product is a tool software specially designed for adjusting the coaxiality of the motor axis and the water pump axis, and is also suitable for the coaxiality detection and adjustment of all mechanical equipment in which the driving shaft and the driven shaft are connected through a coupling to transmit power and torque, helping the unit installation, commissioning personnel and electromechanical maintenance personnel to quickly, efficiently and accurately complete the unit alignment task. The double-meter unit alignment is based on the water pump half coupling, and a magnetic meter holder is installed on its outer cylindrical surface. A radial dial indicator is installed on the outer cylindrical surface of the motor half coupling to measure the radial deviation value of the motor shaft, and an axial dial indicator is installed on the inner side of its end face to measure the axial deviation value of the motor shaft. With the motor side to the water pump side as the observation direction, the clockwise rotation of the coupling is the positive direction, and the radial deviation values ​​of the dial indicator are measured at the four points of the coupling at 0°, 90°, 180° and 270°, respectively, and recorded as a1, a2, a3 and a4, respectively, and the corresponding axial deviation values ​​are recorded as s1, s2, s3 and s4, respectively, and then calculated.

[0060] Furthermore, the main functions of this program product include: data entry, data calculation, data analysis, report export, data preservation and search, etc. It can accurately calculate the thickness of the motor feet plus and minus pads, left and right offsets, etc., and can also determine the actual state of the motor back wheel relative to the water pump back wheel, intuitively and accurately helping engineering and technical personnel to respond quickly.

[0061] The technical features of the software are that this program product is easy to operate, has accurate calculations, has logical judgment capabilities, data storage and other functions, and the saved data can be retrieved and viewed at any time, including the pump station name, water pump and motor model, measurement data and calculation results are all saved in the mobile phone memory, and can also be exported as an Excel spreadsheet and saved to a computer to establish a database and unit file for easy retrieval and viewing at any time.

[0063] The embodiments of the present invention are provided for the purpose of illustration and description. Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations of the present invention. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the present invention.

[0064] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "examples", "specific examples" or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine different embodiments or examples described in this specification and the features of different embodiments or examples, unless they are contradictory.

[0065] In the drawings of the embodiments disclosed in the present invention, only the structures involved in the embodiments disclosed in the present invention are involved, and other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of the present invention can be combined with each other.

[0066] Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A double-meter unit alignment method, characterized in that: The method comprises the following steps: S1. Install a magnetic stand on the outer surface of the pump half coupling; S2. Install a radial dial indicator on the outer surface of the motor half coupling to measure the radial deviation of the motor shaft; S3. Install an axial dial indicator on the inner side of the motor half coupling end face to measure the axial deviation of the motor shaft; S4. Take the clockwise rotation of the coupling as the positive direction, measure the radial deviation values ​​of the dial indicator at the four points of 0°, 90°, 180° and 270° of the coupling, record them as a1, a2, a3, a4, and measure the corresponding axial deviation values, record them as s1, s2, s3, s4; S5. Determine the initial alignment state of the coupling by measuring the initial radial deviation value a 1init , a 2init , a 3init , a 4init and initial axial deviation value s 1init ,s 2init ,s 3init ,s 4init ; S6. Calculate the mean and standard deviation of the initial alignment deviation, and calculate the mean of the radial and axial deviations based on the data of S5. a , Mean s , and the variance of radial and axial deviations StdDev a , StdDev s ; S7. Calculate the cumulative deviation value C of the horizontal deviation h , calculate the cumulative deviation value C of the vertical deviation v ; S8. According to the measurement results, the computer group finds the positions X1, X2, Y1, and Y2.

2. A double-meter unit alignment method as claimed in claim 1, characterized in that: The magnetic meter frame in S1 is made of neodymium iron boron material to provide stable supporting force, and the magnetic meter frame includes an adjustable magnetic control mechanism; the selection and installation of the radial dial indicator in S2 adopts mechanical structure installation and shockproof design, and the installation position of the axial dial indicator in S3 is designed to be a certain distance away from the central axis of the coupling, and the installation adopts a bolt installation method.

3. A double-meter unit alignment method as claimed in claim 2, characterized in that: The calculation method in S6 is: Calculation of the mean and standard deviation of the misalignment helps assess the consistency and range of the initial alignment.

4. A double-meter unit alignment method as claimed in claim 3, characterized in that: The S7 This formula provides the cumulative value of the deviation of the two axes in the horizontal and vertical directions, which helps to further analyze and adjust the spatial position relationship of the two axes.

5. A double-meter unit alignment method as claimed in claim 4, characterized in that: The calculation formula of X1 and X2 in S8 is: When X1>0, "add padding to the front foot"; when X1<0, "reduce padding to the front foot"; when X2>0, "add padding to the back foot"; when X2<0, "reduce padding to the back foot".

6. A double-meter unit alignment method as claimed in claim 5, characterized in that: The calculation formula of Y1 and Y2 in S8 is: When Y1>0, the front foot moves to a2, when Y1<0, the front foot moves to a4, when Y2>0, the back foot moves to a2, and when Y2<0, the back foot moves to a4.

7. A double-meter unit alignment method as claimed in claim 1, characterized in that: In the measurement data of S4, when s1>s3, it is judged as upper opening; when s1=s3, it is judged as two axes are parallel; When s2>s4, it is judged as front opening, and when s2>s4, it is judged as two axes are parallel.

8. A double-meter unit alignment method as claimed in claim 1, characterized in that: The measurement data in S4 must meet the following conditions: a1+a3≈a2+a4; s1+s3≈s2+s4. If the above conditions are not met, the influence of shaft movement or loosening of anchor bolts must be eliminated.

9. A double-meter unit alignment method as claimed in claim 1, characterized in that: The S8 also needs to calculate the total deviation value T of the coupling during the calculation process, which is used to evaluate the overall size of the coupling deviation. The smaller the T value, the higher the coupling alignment accuracy.

10. A double-meter method unit alignment program product, characterized in that: The program product can implement the alignment method described in claims 1 to 9 and has the following functions, characterized in that: The precise measuring unit uses two dial indicators to measure the radial and axial alignment of the coupling to achieve precise measurement; The data analysis unit provides data analysis functions and processes the measured data to ensure the accuracy and reliability of the alignment; Data storage function unit records the process and results of each alignment to facilitate subsequent analysis and optimization; The result judgment unit can judge the concentricity deviation between the motor shaft and the water pump shaft according to the measurement and analysis results, and give adjustment suggestions; The user interface unit allows the user to input measurement values ​​and automatically calculates and displays the adjustment results, with a friendly interface and easy operation.

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